Lincoln Electric IM584-D manual Control Cable Specifications, Available Cable Assemblies

A-4 INSTALLATION A-4

Typical Bench Feeder Connection:

Control cable is connected from the Power Wave 455 output receptacle to the input receptacle on the back of the Wire Drive.

Typical Boom Feeder Connection:

One control cable is connected from the Power Wave 455 output receptacle to the Control Box input recep- tacle. A second control cable is connected from the Control Box output receptacle to the input receptacle on the back of the Wire Drive.

Multiple Wire Drive Connection:

For proper multiple wire drive connections and DIP switch settings contact the Lincoln Electric Company, Customer Service Department. 1-800-833-WELD.

Non-Typical Boom Feeder Connection:

One control cable is connected from the Power Wave 455 output receptacle to the the input receptacle on the back of the Wire Drive. A second control cable is connected from the output receptacle on the back of the Wire Drive to the Control Box input receptacle.

Control Box Mounted on Power Wave 455:

One control cable is connected from the Power Wave 455 output receptacle to the input receptacle on the back of the Wire Drive.

See CONTROL AND ELECTRODE CABLE INSTAL- LATION for cable installation instructions.

CONTROL CABLE SPECIFICATIONS

It is recommended that only genuine Lincoln control cables be used at all times. Lincoln cables are specifi- cally designed for the communication and power needs of the Power Wave 455 / Power Feed system. The use of non-standard cables, especially in lengths greater than 25 feet(7.6 meters), can lead to commu- nication problems (system shutdowns), poor motor acceleration (poor arc starting) and low wire driving force (wire feeding problems).

Lincoln control cables are copper 5 conductor cable in a SO-type rubber jacket. There is one 20 gauge twist- ed pair for network communications. This pair has an impedance of approximately 120 ohms and a propa- gation delay per foot of less than 2.1 nanoseconds. There are two 12 gauge conductors that are used to supply the 40 VDC to the network. The fifth wire is 18 gauge and is used as an electrode sense lead.

AVAILABLE CABLE ASSEMBLIES

K1543 Control cable only. Available in lengths of 8'(2.4m), 16'(4.9m), 25'(7.6m), 50'(15.2m) and 100'(30.5m).

K1544 Control cable and a 3/0 (85 mm2 ) electrode cable with stud terminal. It is rated at 600 amps, 60% duty cycle and is available in lengths of 8'(2.4m), 16'(4.9m), 25'(7.6m), 50'(15.2m).

K1545 Control cable and a 3/0 (85 mm2) electrode cable with Twist-Mate™ connector on one end and a stud terminal on the other. It is rated at 500 amps, 60% duty cycle and is available in lengths of 8'(2.4m), 16'(4.9m), 25'(7.6m), 50'(15.2m).

ELECTRODE CABLE CONNECTIONS

Most welding applications run with the electrode being positive (+). For those applications, connect the elec- trode cable between the wire feeder and the positive

(+)output stud on the power source (located beneath the spring loaded output cover near the bottom of the case front).

For positive porosity application, a work lead must be run from the negative (-) power source output stud to the work piece. The work piece connection must be firm and secure, especially if pulse welding is planned. Excessive voltage drops at the work piece connection often result in unsatisfactory pulse welding perfor- mance.

When negative electrode polarity is required, such as in some Innershield™ applications, install as above, except reverse the output connections at the power source (electrode cable to the negative (-) stud, and work cable to the positive (+) stud).

Change electrode polarity Dip Switch in Feed Head, (see Dip Switch Setup Section).

POWER FEED 10